KawasakiJ300

J300J300ABSThisquickreferenceguidewillassistyouinlocatingadesiredtopicorpro-cedure.•Bendthepagesbacktomatchtheblacktabofthedesiredchapternum-berwiththeblacktabontheedgeateachtableofcontentspage.•Refertothesectionaltableofcontentsfortheexactpagestolocatethespe-cifictopicrequired.QuickReferenceGuideGeneralInformation1jPeriodicMaintenance2jFuelSystem(DFI)3jCoolingSystem4jEngineTopEnd5jConverterSystem6jEngineLubricationSystem7jEngineRemoval/Installation8jCrankcase/Crankshaft9jWheels/Tires10jFinalDrive11jBrakes12jSuspension13jSteering14jFrame15jElectricalSystem16jAppendix17jJ300J300ABSMotorcycleServiceManualAllrightsreserved.Nopartsofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans,electronicmechanicalphotocopying,recordingorotherwise,withoutthepriorwrittenpermissionofQualityAssuranceDivision/Motorcycle&EngineCompany/KawasakiHeavyIndustries,Ltd.,Japan.Noliabilitycanbeacceptedforanyinaccuraciesoromissionsinthispublication,althougheverypossiblecarehasbeentakentomakeitascompleteandaccurateaspossible.Therightisreservedtomakechangesatanytimewithoutpriornoticeandwithoutincurringanobligationtomakesuchchangestoproductsmanufacturedpreviously.SeeyourMotorcycledealerforthelatestinformationonproductimprovementsincorporatedafterthispublication.Allinformationcontainedinthispublicationisbasedonthelatestproductinformationavailableatthetimeofpublication.Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmaynotdepictactualmodelcomponentparts.©2013KawasakiHeavyIndustries,Ltd.2ndEdition(1):Jul.10,2014LISTOFABBREVIATIONSAampere(s)kg(mass)ABDCafterbottomdeadcenterkgf(force)ACalternatingcurrentkm/hkilometersperhourAhamperehourLliter(s)ATDCaftertopdeadcenterlbpound(s)BBDCbeforebottomdeadcentermmeter(s)BDCbottomdeadcenterminminute(s)BTDCbeforetopdeadcenterNnewton(s)°Cdegree(s)Celsiusozounce(s)CDIcapacitivedischargeignitionPapascal(s)cmHgcentimetersofmercuryPShorsepowercuin.cubicinch(es)psipound(s)persquareinchDCdirectcurrentqtquart(s)EMIElectro-MagneticInterferencerrevolutionFfarad(s)r/min,rpmrevolution(s)perminute°Fdegree(s)Fahrenheitssecond(s)ftfoot,feetSOHCsingleoverheadcamshaftggram(s)(mass)TDCtopdeadcentergalgallon(s)TIRtotalindicatorreadinghhour(s)Vvolt(s)HPhorsepower(s)Wwatt(s)in.inch(es)Ωohm(s)ISCIdleSpeedControlForewordThismanualisdesignedprimarilyforusebytrainedmechanicsinaproperlyequippedshop.However,itcontainsenoughdetailandbasicin-formationtomakeitusefultotheownerwhode-sirestoperformhisownbasicmaintenanceandrepairwork.Abasicknowledgeofmechanics,theproperuseoftools,andworkshopproce-duresmustbeunderstoodinordertocarryoutmaintenanceandrepairsatisfactorily.When-evertheownerhasinsufficientexperienceordoubtshisabilitytodothework,alladjust-ments,maintenance,andrepairshouldbecar-riedoutonlybyqualifiedmechanics.Inordertoperformtheworkefficientlyandtoavoidcostlymistakes,readthetext,thor-oughlyfamiliarizeyourselfwiththeproceduresbeforestartingwork,andthendotheworkcare-fullyinacleanarea.Wheneverspecialtoolsorequipmentarespecified,donotusemakeshifttoolsorequipment.Precisionmeasurementscanonlybemadeiftheproperinstrumentsareused,andtheuseofsubstitutetoolsmayad-verselyaffectsafeoperation.Forthedurationofthewarrantyperiod,werecommendthatallrepairsandscheduledmaintenancebeperformedinaccordancewiththisservicemanual.Anyownermaintenanceorrepairprocedurenotperformedinaccordancewiththismanualmayvoidthewarranty.Togetthelongestlifeoutofyourvehicle.•FollowthePeriodicMaintenanceChartintheServiceManual.•Bealertforproblemsandnon-scheduledmaintenance.•UsepropertoolsandgenuineKawasakiMo-torcycleparts.Specialtools,gauges,andtestersthatarenecessarywhenservicingKawasakimotorcyclesareintroducedbytheServiceManual.GenuinepartsprovidedassparepartsarelistedinthePartsCatalog.•Followtheproceduresinthismanualcare-fully.Don’ttakeshortcuts.•Remembertokeepcompleterecordsofmain-tenanceandrepairwithdatesandanynewpartsinstalled.HowtoUseThisManualInthismanual,theproductisdividedintoitsmajorsystemsandthesesystemsmakeupthemanual’schapters.TheQuickReferenceGuideshowsyoualloftheproduct’ssystemandassistsinlocatingtheirchapters.EachchapterinturnhasitsowncomprehensiveTa-bleofContents.Forexample,ifyouwantignitioncoilinforma-tion,usetheQuickReferenceGuidetolocatetheElectricalSystemchapter.Then,usetheTableofContentsonthefirstpageofthechap-tertofindtheIgnitionCoilsection.Wheneveryouseesymbols,heedtheirin-structions!Alwaysfollowsafeoperatingandmaintenancepractices.DANGERDANGERindicatesahazardoussitua-tionwhich,ifnotavoided,willresultindeathorseriousinjury.WARNINGWARNINGindicatesahazardoussitua-tionwhich,ifnotavoided,couldresultindeathorseriousinjury.NOTICENOTICEisusedtoaddresspracticesnotrelatedtopersonalinjury.Thismanualcontainsfourmoresymbolswhichwillhelpyoudistinguishdifferenttypesofinformation.NOTE○NOTEindicatesinformationthatmayhelporguideyouintheoperationorserviceofthevehicle.•Indicatesaproceduralsteporworktobedone.○Indicatesaproceduralsub-steporhowtodotheworkoftheproceduralstepitfollows.Italsoprecedesthetextof